Refrigerant with lubricating oil for replacement of r22 refrigerant

ABSTRACT

An apparatus and method wherein potential ozone layer-damaging chlorodifluoromethane (Refrigerant R-22) is substituted with a mix of less environmentally damaging refrigerants pentafluoroethane and tetrafluoroethane in chlorodifluoromethane-based air-cooling systems mainly in residential cooling. While less environmentally damaging than chlorodifluoromethane, the substitute refrigerant has a temperature-pressure relationship similar to that of chlorodifluoromethane, making the substitute refrigerant suitable for use with chlorodifluoromethane-based air-cooling systems. In this event, it is mixed with a relatively small percentage of a lubricating oil which is compatible with both the unit refrigerant and typical R-22 system design.

RELATED APPLICATION

This application, mineral oil, synthetic alkyl aromatic lubricants, andmixtures thereof is a continuation of U.S. patent application Ser. No.12/961,045 filed Dec. 6, 2010, which is a continuation of U.S. patentapplication Ser. No. 10/937,736 filed Sep. 8, 2004, which claimspriority to and the benefit of provisional application Ser. No.60/501,049 filed Sep. 8, 2003.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to the replacement of Refrigerant R-22(chlorodifluoromethane) refrigerant with a blend refrigerant that isless damaging to the ozone layer in systems designed to use RefrigerantR-22 (chlorodifluoromethane). More particularly the present inventionrelates to an improved refrigerant composition, method and apparatus forrefrigeration wherein two non-Refrigerant R-22 refrigerants are mixed ina defined ratio such that the temperature-pressure relationship of themix approximates that of Refrigerant R-22 (chlorodifluoromethane). Themixture is compatible with Refrigerant R-22 (chlorodifluoromethane) sothat it can be added to supplement and replace Refrigerant R-22(chlorodifluoromethane). A further particularity of the instantinvention relates to an improved method and apparatus for refrigerationwherein refrigerant mixture is mixed with a soluble lubricating oil toprovide lubrication to the apparatus. The lubricant is soluble in boththe mixture of the invention and Refrigerant R-22(chlorodifluoromethane) refrigerant.

2. General Background

Until recently, R-22 refrigerant chlorodifluoromethane (hereinaftersometimes called “Refrigerant R-22 (chlorodifluoromethane)”) was themajor, if not sole refrigerant, used in residential air-conditioners,refrigerators, freezers and window air-conditioning units. RefrigerantR-22 (chlorodifluoromethane) is a trademark of E. I. du Pont de Nemours& Co. Inc. for chlorodifluoromethane. Hereinafter, “Refrigerant R-22(chlorodifluoromethane)” is used in this specification to denotechlorodifluoromethane, regardless of the source.

Recently, however, Refrigerant R-22 (chlorodifluoromethane) has comeunder attack both nationally and internationally as an ozonelayer-damaging chemical. In recent years, both the national andinternational scientific communities have linked Refrigerant R-22(chlorodifluoromethane) with damage to the earth's protective ozonelayer. Air-conditioners, refrigerator/freezers and windowair-conditioning units containing R-22 are believed to be a globalsource of ozone-damaging material.

In response to scientific concern and a national and global outcry overthe use of Refrigerant R-22 (chlorodifluoromethane) in air-conditioning,the United States Congress has acted to first reduce and then ban theuse of Refrigerant R-22 (chlorodifluoromethane) in air-conditioningunits.

As a first step toward phasing out the use of Refrigerant R-22(chlorodifluoromethane) in air-conditioning units, Congress is phasingout the use of Refrigerant R-22 (chlorodifluoromethane) in new equipmenteffective Jan. 1, 2015 and has banned the sale of Refrigerant R-22(chlorodifluoromethane) in any size container as of Jan. 1, 2020. One ofthe first areas in which the use of Refrigerant R-22(chlorodifluoromethane) is to be phased out is in the Bakery industryunder the Bakery Partnership Program. Another step in phasing out theuse of R-22 is the import restrictions that begin in 2003, limiting theamount of R-22 that can be imported into the United States.

At the time of this application, the vast majority of residential,window units and freezers in use in the United States containRefrigerant R-22 (chlorodifluoromethane).

Prior to banning the sale of quantities of Refrigerant R-22(chlorodifluoromethane), owners of equipment with Refrigerant R-22(chlorodifluoromethane)-based air-conditioning units are able topurchase the level of refrigerant in their equipment with only the needof a refrigerants license as required by the Clean Air Act. Millions ofunits containing refrigerant R-22 (chlorodifluoromethane) were sold inthe United States prior to the start of mandatory phase out set forth byCongress and the international community.

Refrigerant R-22 (chlorodifluoromethane) recharging typically involves30 lb. cans or cylinders typically used in the HVAC/R industry. Thecylinders are fitted with a dispensing outlet compatible with acommercially available refrigeration manifold. In order to recharge anair-conditioning system, a customer need to only fit the can or cylinderto the manifold and discharge, or “add to” the refrigerant chargedirectly into the air conditioning system.

Following Congress's ban on the sale of Refrigerant R-22(chlorodifluoromethane) millions of equipment owners with RefrigerantR-22 (chlorodifluoromethane)-based air-conditioning units will be leftwith no choice other than to seek replacement refrigerants to servicethese units. Intentionally mixing of refrigerants is currently illegalby standards set forth by the Clean Air Act. An example would be forthis application is that current R-22 units could not be mixed with thisinvention intentionally.

In response to Congress's ban on the use of Refrigerant R-22(chlorodifluoromethane) in air-conditioning, service dealers have beganto retrofit existing Refrigerant R-22 (chlorodifluoromethane)-basedair-conditioning units with new, non-R-22 refrigerants, such as R410A (a50/50 mixture of difluoromethane and pentafluoroethane), R417 (a 46/50/4mixture of pentafluoroethane, 1,1,1,2-tetrafluoroethane, and butane) orR407C (a 23/25/52 mixture of difluoromethane, pentafluoroethane, and1,1,1,2-tetrafluoroethane). None of these replacements contain alubricant when produced.

The refrigerants that will be authorized by the Environmental ProtectionAgency (EPA) to replace Refrigerant R-22 (chlorodifluoromethane) in airconditioners is currently under review and will evolve to require aenvironmentally safe refrigerant, with a 0 odp factor like the one ofthe present invention described herein. Unfortunately, most replacementsfor R-22 have a markedly different temperature-pressure relationship atmost operating temperatures than Refrigerant R-22(chlorodifluoromethane).

Because of this difference in the temperature-pressure relationship ofRefrigerant R-22 (chlorodifluoromethane) and current replacementrefrigerants, existing Refrigerant R-22 (chlorodifluoromethane)-basedsystems cannot typically be interchanged. Hence, non-retrofitted,Refrigerant R-22 (chlorodifluoromethane)-based units have a need for arefrigerant that will fulfill the requirements of the system designwhile also meeting the requirements of the EPA and the internationalcommunity.

Simply mixing refrigerants with existing Refrigerant R-22(chlorodifluoromethane) in order to replenish, or “toping off” the levelis against the law and not feasible. When other refrigerants are mixedwith Refrigerant R-22 (chlorodifluoromethane), the mixture can take onthe pressure characteristics of a substance that could be harmful toeither the equipment or the operator. The temperature-pressurerelationship becomes markedly different from that of Refrigerant R-22(chlorodifluoromethane) at temperatures within the normal refrigerantoperating temperature range and typical use of R-22.

Hence, in the absence of Refrigerant R-22 (chlorodifluoromethane) ownersof equipment with Refrigerant R-22 (chlorodifluoromethane)-based airconditioners face but one choice when the level of theirair-conditioning coolant is low: professional service—at a significantcost—to remove the existing Refrigerant R-22 (chlorodifluoromethane),and retrofit the system compatible with some kind of refrigerant gas.

R-22 refrigerants were developed to replace the prior, now banned R-12refrigerant, or dichlorodifluoromethane. R-12 is sometimes referred toas FREON 12®, which is a trademark of E.I. du Pont de Nemours & Co. fordichlorodifluoromethane.

Thomas et al. (U.S. Pat. No. 5,254,280) discloses a lubricant developedfor use with a refrigerant known as R134a (1,1,1,2-tetrafluoroethane)and the combination of that lubricant with a refrigerant, which is areplacement for R-12. The lubricant contains polyoxyalkylene glycol,which is hydrophilic and could damage the system as discussed below.

Wilczek (U.S. Pat. No. 5,384,057), Gorski (U.S. Pat. No. 4,971,712), andAnton of DuPont (U.S. Pat. No. 5,145,594) disclose other R-12replacements in the form of a blend of certain synthetic lubricants invarious R134a and R134a/R125 refrigerant systems. The DuPont patentsdiscuss a gas known as R125 (pentafluoroethane). R125 is five fluorineatoms bonded to an ethane molecule. This is a very large molecule for arefrigerant. It is currently being produced for refrigeration only.Anton discloses the use of a lubricant comprising at least onecyanocarbon compound. Wilczek discloses a fluorosiloxane as a lubricant.Gorski discloses a polyakylene glycol as a lubricant.

Systems that contain R-22, or R-12 replacements, are still beingproduced today. These older systems have common components: R-22, R-22mineral oil lubricant, and water that is sequestered into the dryer. IfR134a (1,1,1,2-tetrafluoroethane) were added to the system, it woulddamage the system as follows: (1) if no lubricant is added to the R134a(as in U.S. Pat. No. 4,953,312 to Tamura et al.), then the R-22 systemwould be starved for lubricant, since the R134a gas is not miscible withthe mineral oil lubricant; (2) if a synthetic lubricant is added to theR134a (as in Thomas et al.), then there is a different problem—that ofmoisture. Older systems can have water trapped in their dryers. Thesynthetic lubricants (such as polyglycol- or polysiloxane-basedlubricants) are hydrophilic. Thus, they are not only miscible with R-22and R134a; they are also partially or completely miscible with water.Thus, if they are introduced into an R-22 system, they will pull thiswater out of the dryer into the refrigerant flow, initiating corrosionand damage to pressure switches and the TX valve and possible othersystem components. This is why Elf Atochem and DuPont, to name a fewpublish elaborate flushing procedures and high efficiency dryerchange-outs to prevent damage to the cooling system.

Weber (U.S. Pat. No. 5,942,149) discloses yet another R-12 replacementconsisting of a blend of chlorodifluoroethane, tetrafluoroethane and anapthenic lubricating oil.

SUMMARY OF THE PRESENT DISCLOSURE

The present disclosure is of a method and apparatus that areenvironmentally sound alternatives to the use of Refrigerant R-22(chlorodifluoromethane) as a refrigerant. More particularly, theinvention provides a mixture of at least two refrigerants that aremiscible with each other, and compatible with Refrigerant R-22(chlorodifluoromethane) while at the same time possessing atemperature-pressure profile that approximates that of Refrigerant R-22(chlorodifluoromethane) over the operating range of ambient temperaturesusually encountered by air conditioning units or other apparatusutilizing Refrigerant R-22 (chlorodifluoromethane) as a refrigerant. Theinvention also provides a lubricant, that is compatible with both theenvironmentally sound refrigerant of the invention and with RefrigerantR-22 (chlorodifluoromethane), so that mixtures of the refrigerantaccording to the invention and Refrigerant R-22 (chlorodifluoromethane)may be utilized with this lubricant in the refrigeration systems withoutdeleterious effect upon moving parts of the refrigerating apparatus thatrequire lubrication from the refrigerant.

More particularly, the refrigerant and method disclosed herein involvesa mixture of pentafluoroethane and tetrafluoroethane in specificproportions that provide a temperature-pressure relationship thatapproximates that of Refrigerant R-22 (chlorodifluoromethane) over therange of ambient temperature operating conditions in which RefrigerantR-22 (chlorodifluoromethane) is a useful refrigerant. Thepentafluoroethane/tetrafluoroethane refrigerant blend disclosed hereinis compatible with both synthetic and mineral oils. Thetetrafluoroethane can be either 1,1,1,2-tetrafluoroethane or1,1,2,2-tetrafluoroethane. In an exemplary embodiment, the refrigerantaccording to the invention comprises a ratio of from about 40 to about45 weight percent pentafluoroethane to about 55 to about 60 percent1,1,1,2-tetrafluoroethane, based upon the total weight ofpentafluoroethane and 1,1,1,2-tetrafluoroethane. In a further exemplaryembodiment, the refrigerant includes the ratio of about 42 weightpercent pentafluoroethane to about 58 weight percent1,1,1,2-tetrafluoroethane.

In addition, the refrigerant according to the invention also includesfrom about 0 to about 20 weight percent (based on the combined weight ofpentafluoroethane and 1,1,1,2-tetrafluoroethane) of a lubricating oilthat is soluble in chlorodifluoromethane, pentafluoroethane, and1,1,1,2-tetrafluoroethane. In a preferred embodiment the lubricating oilis present in the range of from about 0.5 to about 2% by weight of therefrigerant mixture.

In an exemplary embodiment, the lubricating oil is a napthenic orparaffinic based lubricating oil. In a further exemplary embodiment, thelubricant is selected from those lubricants sold by Anderol, Inc., EastHanover, N.J., an affiliate of Royal Lubricants Company, under thetrademark ROYCO® 2302. ROYCO® 2302 is a napthenic oil lubricant havingthe following composition:

65-85% hydrotreated light napthenic distillate,

10-20% solvent refined light napthenic distillate petroleum,

<0.5% butylated triphenyl phosphate, and

<2% minor additive.

In another exemplary embodiment, the lubricating oil can be a syntheticlubricating oil, or a mixture of oils, that is soluble in the mixture ofthe chlorodifluoroethane and tetrafluoroethane. A suitable syntheticlubricant is a man-made, synthetic alkyl aromatic lubricant. Suitablesynthetic lubricants include alkylated benzene lubricants.

The lubricant can be either a synthetic alkyl aromatic lubricant, suchas alkylbenzene, alone, or a mixture of a synthetic alkyl aromaticlubricant and mineral oil or a mixture of a synthetic alkyl aromaticlubricant and polyol ester (POE). When so mixed, it is preferred, butnot required, that a minor portion of the mixture be mineral oil or POE.By minor portion, we mean less than 50% by weight of the blendedrefrigerants. Alternatively, either mineral oil or polyol ester (POE)can be used alone.

While it is intended that the substitute refrigerant according to theinvention may be utilized to replace Refrigerant R-22(chlorodifluoromethane) that has escaped from apparatus, the substituterefrigerant of the invention may also be utilized to completely refillapparatus that have been designed for use with Refrigerant R-22(chlorodifluoromethane), since the refrigerant has atemperature-pressure profile that closely approximates that ofRefrigerant R-22 (chlorodifluoromethane). Thus, when the refrigerant isused as a complete replacement for Refrigerant R-22(chlorodifluoromethane), it is no longer necessary that the lubricant becompatible with chlorodifluoromethane but only that it should becompatible with 1,1,1,2-tetrafluoroethane and pentafluoroethane.

Further, whereas the substitute refrigerant of the invention is lessdamaging to the ozone layer than Refrigerant R-22(chlorodifluoromethane) and is useful in air conditioning units, and inparticular residential type air-conditioning units, it is not so limitedin its use. Indeed, the refrigerant may be utilized as a substitute orreplacement for Refrigerant R-22 (chlorodifluoromethane) in virtuallyany application, thereby eliminating the use of ozone layer-damagingRefrigerant R-22 (chlorodifluoromethane).

In further specifics, the invention provides a canister containing amixture of tetrafluoroethane and pentafluoroethane with a napthenic oilthat may be fitted with an outlet manifold that is compatible with aRefrigerant R-22 (chlorodifluoromethane) recharging manifold that istypically used to recharge an apparatus with the latter refrigerant.Refrigerant may then be allowed to flow from the container through themanifold and into the apparatus to replace Refrigerant R-22(chlorodifluoromethane) refrigerant that has been lost from therefrigeration system.

When mixing the components of the refrigerant blend of the presentinvention, one should first mix the lubricant with thetetrafluoroethane, then mix that mixture with the pentafluoroethane inthe proportions afore mentioned. Otherwise, the product does not mixproperly.

In an exemplary form, the lubricant has a viscosity of 5 to 500centistokes, more preferably 5 to 100 centistokes, even more preferably5 to 50 centistokes, and most preferably 5 to 10 centistokes. Thelubricant having a viscosity of 5 to 10 centistokes is preferred.

In an exemplary embodiment, the percentage by weight of lubricant in therefrigerant blend is 0-20%, preferably 0.5-2%, more preferably 1-2%,even more preferably 1.25-2%, and most preferably 1.5-1.75%. Thepercentage by weight of lubricant in the refrigerant blend is, forexample, 1.75.+−0.0.05%.

A suitable lubricant is severely hydro treated napthenic/paraffiniclubricant, such as the aforementioned ROYCO® 2302. Other suitablelubricants include Sunpar R2280 (a paraffinic based lubricant), Lubrizol403, Sunthene 200 (a napthenic based lubricant) and L30 or L35 fromShrieve Chemical Company, The Woodlands, Tex., or Zerol 150 fromNu-Calgon Wholesale, Inc., St. Louis, Mo., or AB150 from Virginia KMPCorporation, Dallas, Tex. (alkylbenzene synthetic lubricants). Mobil One5-weight synthetic oil (it is hydrophobic) could also work as alubricant, but it is relatively expensive.

In order for the parts of the refrigerant system to function best,0.5-20% of total weight of refrigerant should be lubricant. When addingthe refrigerant blend to a refrigerant system, one should leave thelubricant in the system if one for some reason takes out the RefrigerantR-22.

The lubricating of the present system is miscible with thepentafluoroethane and tetrafluoroethane blend and with R-22 refrigerant.This allows for mixing of residual R-22 refrigerant and the refrigerantof the present invention, without the release of significant amounts ofresidual water in the dryer and subsequent system damage (as will happenif the synthetic lubricants disclosed in Thomas et al. and the DuPontpatents are used). While alkylbenzene alone is considered not misciblewith tetrafluoroethane (in particular R134a), it is sufficiently solublein the present tetrafluoroethane/chlorodifluoroethane mixture. Thissolubility allows the replacement refrigerant blend to lubricate thesystem, preventing damage to the compressor and component parts of thesystem.

Various optional additives can be included in the lubricant. A corrosioninhibitor can be included. (otherwise corrosion will probably occurwithin 6 months). An exemplary corrosion inhibitor is one for anhydroussystems (such corrosion inhibitors comprise calcium, or phosphatesalts). The corrosion inhibitor can be bonded to the lubricant.Additionally, a surfactant and/or a foaming agent can be included.

The present refrigerant blend is designed to be utilized as a R-22replacement in refrigeration systems. It is designed as a replacement,in which little or no modifications including parts are used to adaptthe system for the refrigerant of the present invention.

The present refrigerant blend can be used as a replacement for R-22refrigerant, typically deminimus without retrofitting the airconditioning system or flushing it out. It is recommended that a fullvacuum be obtained before adding the refrigerant to the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the disclosure can be better understood with referenceto the following drawings.

FIG. 1 illustrates pressure versus temperature profiles for variousblends of the present disclosure in comparison to R-22.

FIG. 2 compares the temperature versus enthalpy profile of an exemplaryembodiment of the present disclosure to R-22.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present disclosure provides a mixture of non-Refrigerant 22refrigerants that are less damaging to the Earth's ozone layer and thatare approved by the U.S. Environmental Protection Agency for use inair-conditioners. The invention mixture is compatible with RefrigerantR-22 (chlorodifluoromethane) and can be used to replace existingRefrigerant R-22 (chlorodifluoromethane)—in R-22 based refrigerationsystems. It is expected that the present invention will graduallyreplace Refrigerant R-22 (chlorodifluoromethane) in Refrigerant R-22(chlorodifluoromethane)-based air-cooling systems, without the need toretrofit existing Refrigerant R-22 (chlorodifluoromethane)-based systemsfor non-Refrigerant 22 replacement refrigerants.

Specifically, the present refrigerant blend includes a mixture ofpentafluoroethane and tetrafluoroethane packaged with a compatiblelubricating oil, provided under pressure in a can or cylinder equippedwith an outlet compatible with existing Refrigerant R-22(chlorodifluoromethane) recharging kit manifolds, so that therefrigerant and lubricant mixture can be added to existing RefrigerantR-22 (chlorodifluoromethane) based coolant systems. Also, the inventionprovides the possibility of using new refrigerant systems, originallydesigned for “Refrigerant R-22 (chlorodifluoromethane),” by supplying anEPA-approved refrigerant so that retrofitting to new equipment use isnot required.

In an exemplary embodiment, the invention provides a cylinder can likethe standard 25 or 30 lb. can formerly used for containing “RefrigerantR-22 (chlorodifluoromethane),” but containing about 58% by weight1,1,1,2-tetrafluoroethane and about 42% by weight pentafluoroethane. Thecan also contains the preferred lubricant, ROYCO® 2302 in solution withthe coolant mixture at a percent by weight of between 0.5% and 2%.

Existing Refrigerant R-22 (chlorodifluoromethane)-based air-conditioningsystems use an amount of a vegetable or hydrocarbon mineral oil tolubricate the compressor. This oil has a very low vapor pressure, and isnot soluble with pure tetrafluoroethane, particularly1,1,1,2-tetrafluoroethane. Hence, adding tetrafluoroethane to replaceRefrigerant R-22 (chlorodifluoromethane) in existing Refrigerant R-22(chlorodifluoromethane)-based air-conditioning systems leads tocompressor breakdown from lack of sufficient lubrication. The inventionprovides lubricants that are compatible with the invention mixture oftetrafluoroethane and pentafluoroethane, and with “Refrigerant R-22(chlorodifluoromethane),” and that are suitable for lubricatingrefrigerant compressors and other air-conditioner component parts. Thelubricants disclosed herein, on the other hand, are soluble in atetrafluoroethane/pentafluoroethane mixture. This solubility allows thereplacement refrigerant blend to lubricate the air-conditioning system,preventing damage to the compressor and component parts of the system.

Example 1

Table 1 summarizes the results of solubility tests of a 2% by weightsolution of ROYCO® 2302 oil lubricant in an 58/42% by weight mixture of1,1,1,2-tetrafluoroethane and pentafluoroethane refrigerants. ROYCO®2302 oil (available from ANDEROL®, Inc., an affiliate of RoyalLubricants Co.), was added to a clear Fisher-Porter pressure burette anda mixture of 1,1,1,2-tetrafluoroethane/pentafluoroethane in an 58/42ratio by weight was introduced under pressure to maintain the liquidstate.

TABLE 1 Full Burette clear no separation ⅔ Full Burette clear noseparation ½ Full Burette clear no separation ⅓ Full Burette clear noseparation Almost Empty Burette clear no separation Note: The color ofthe fluid remained the same as the burette was emptied. The expelled gasdeposited the oil onto a test panel.

Example 2

1,1,1,2-tetrafluoroethane and pentafluoroethane are mixed with thenapthenic oil lubricant at set ratios such that the temperature-pressureprofile of the mixture is similar to that of Refrigerant R-22(chlorodifluoromethane), over the normal operating range ofair-conditioners. Table 2 summarizes the results of tests of thetemperature-pressure profiles of various mixes of1,1,1,2-tetrafluoroethane and pentafluoroethane over the range of normalair-conditioner working temperatures, from −60 degree. F. to 160.degree. F.

For Table 2, different percentages of 1,1,1,2-tetrafluoroethane andpentafluoroethane—by weight—were mixed with the lubricant to show thepressure temperature relationships of the various inventioncombinations.

FIG. 1 shows Pressure (liquid) vs. Temperature profiles for R-22 andblends of 40/60, 45/55 and 42/58 of tetrafluoroethane andpentafluoroethane, respectively.

FIG. 2 shows Temperature vs. Enthalpy profiles comparing a blend of40/60 tetrafluoroethane and pentafluoroethane to R-22.

The blend of refrigerants tetrafluoroethane and pentafluoroethane of thepresent disclosure shows the following properties of interest:

Dew Point @−32 F

Bubble Point @−41.5 F

Glide @ 9.5 F

An exemplary blend of refrigerants is about 42% by weightpentafluoroethane and about 58% by weight 1,1,1,2-tetrafluoroethane.This is the ratio of pentafluoroethane to 1,1,1,2-tetrafluoroethane withthe lubricant where the mixture of the invention shows the greatestsimilarity to “Refrigerant R-22 (chlorodifluoromethane)”, over mostoperating temperatures.

The apparatus and method of the preferred embodiment encompass the useof a mixture of 1,1,1,2-tetrafluoroethane and pentafluoroethane at theranges, as discussed above, with a lubricating oil at ranges, asdiscussed above of about 0.5% to about 2% by weight in the operation ofan air-conditioning system, wherein the coolant-oil mixture replacesRefrigerant R-22 (chlorodifluoromethane) in a Refrigerant R-22(chlorodifluoromethane)-based refrigeration system.

The method and apparatus in the preferred embodiment further detailsproviding the above described mix ofpentafluoroethane/1,1,1,2-tetrafluoroethane and lubricating oil in 30lb. cylinders, where the cylinders are pressure sealed and fitted withan outlet compatible for existing Refrigerant 22-type refrigerationmanifolds typically ¼ inch male flare.

Further, it was noted that the systems tested ran more smoothly and thecompressor showed less vibration during the test period, as the mixtureof the invention was added. It is theorized that the lubricating oil,being soluble in the refrigerant gasses, was better able to lubricatethe compressor and reciprocating parts than the existing RefrigerantR-22 (chlorodifluoromethane) lubricant used by itself. In someapplications a reduction in power consumption maybe also noted.

The refrigerant of the present invention can also be used as areplacement refrigerant for the new R-22 air-conditioning systems, suchas the systems used in today's HFC-free units

The ROYCO® 2302 napthenic oil lubricant of the present disclosure has aflash point of more than 150 degrees F. Pure refrigerant1,1,1,2-tetrafluoroethane is not miscible with a napthenic lubricantlike mineral oil or mineral seal oil (both of which could be used as thelubricants of the present invention). Pentafluoroethane is miscible withmost napthenic lubricants, including mineral oils. The presence of thepentafluoroethane allows the use of mineral oils in the refrigerantblend and system of the present invention (a translucent, partiallymiscible blend is formed). The lubricant can advantageously be partiallypolymerized into longer chain molecules to allow it to function at verylow percentage levels. The lubricant can be hydrotreated or polymerizedfor stability and wear resistance.

Phosphated additives add corrosion resistance in the presence of acidsand salts and increase wear resistance. Calcium additives help thelubricant resist rust and the effects of corrosion; calcium salts reducethe corrosive effects of hydrochloric acid that is formed in thepresence of water and the chlorinated gases present in the refrigerantsystems of the present invention.

The ROYCO® lubricants mentioned above contain the corrosion inhibitorsmentioned above and can also contain acrylic polymer. It is believedthat the function of the acrylic polymer is to increase wear resistanceunder severe conditions. Acrylics can help film formation, and theability of the lubricant to coat metal and soft parts and stay in place.

The lubricant of the present invention is miscible with R-22, the R-22lubricant, and the blend of the refrigerant gases of the presentinvention.

It should be understood that variations and modifications may be made ofthe invention herein taught, and that those are within the scope andspirit of the invention as taught above and claimed here below.

TABLE 2 Temp (F.) P (60-40) P (58-42) P (55-45) P (R-22) −60 8.982 8.818.552 8.836 −55 10.36 10.16 9.87 10.19 −50 11.9 11.68 11.35 11.7 −4513.62 13.37 12.99 13.39 −40 15.52 15.24 14.82 15.26 −35 17.63 17.3216.84 17.34 −30 19.96 19.61 19.08 19.62 −25 22.52 22.13 21.54 22.14 −2025.33 24.9 24.25 24.91 −15 28.41 27.93 27.21 27.93 −10 31.76 31.23 30.4431.23 −5 35.42 34.83 33.96 34.82 0 39.39 38.74 37.79 38.73 5 43.69 42.9841.94 42.96 10 48.34 47.57 46.43 47.54 15 53.36 52.52 51.27 52.48 2058.76 57.85 56.5 57.79 25 64.57 63.58 62.11 63.51 30 70.8 69.73 68.1469.65 35 77.48 76.33 74.61 76.22 40 84.62 83.38 81.52 83.26 45 92.2590.9 88.91 90.76 50 100.4 98.93 96.79 98.76 55 109 107.5 105.2 107.3 60118.2 116.6 114.1 116.3 65 128 126.2 123.6 125.9 70 138.4 136.5 133.6136.1 75 149.3 147.3 144.3 146.9 80 160.9 158.8 155.6 158.3 85 173.2170.9 167.5 170.4 90 186.1 183.7 180.1 183.1 95 199.8 197.2 193.3 196.5100 214.2 211.4 207.3 210.6 105 229.3 226.4 222.1 225.5 110 245.3 242.2237.6 241.1 115 262 258.7 253.9 257.5 120 279.6 276.1 271 274.7 125298.1 294.4 289 292.7 130 317.5 313.6 307.8 311.6 135 337.8 333.7 327.6331.4 140 359.1 354.8 348.3 352.1 145 381.4 376.8 370.1 373.7 150 404.8400 392.8 396.4 155 429.3 424.2 416.7 420 160 454.9 449.5 441.6 444.7

1.-29. (canceled)
 30. In an apparatus designed for use withchlorodifluoromethane refrigerant, the improvement comprisingsubstituting the chlorodifluoromethane with a refrigerant compositiondesigned to achieve a phase change, the refrigerant compositioncomprising a combination of refrigerant gases, said refrigerant gasesconsisting of a blend of tetrafluoroethane and pentafluoroethane,wherein in the substitute refrigerant said pentafluoroethane is presentin an amount of 59% to 57% by weight and said tetrafluoroethane ispresent in an amount of 41% to 43% by weight of the combined weight ofthe pentafluoroethane and tetrafluoroethane on the basis of the combinedweights of said pentafluoroethane and said tetrafluoroethane totaling100%, and wherein the tetrafluoroethane is 1,1,1,2-tetrafluoroethane.31. (canceled)
 32. A method for refilling an apparatus designed for usewith a chlorodifluoromethane refrigerant, the method comprising: (1)selecting a substitute refrigerant composition designed to achieve aphase change and comprising a combination of refrigerant gases, therefrigerant gases consisting of a blend of tetrafluoroethane andpentafluoroethane, wherein in the substitute refrigerant saidpentafluoroethane is present in an amount of 59% to 57% by weight andsaid tetrafluoroethane is present in an amount of 41% to 43% by weightof the combined weight of the pentafluoroethane and tetrafluoroethane onthe basis of the combined weights of said pentafluoroethane and saidtetrafluoroethane totaling 100%, and wherein the tetrafluoroethane is1,1,1,2-tetrafluoroethane, and (2) supplying the substitute refrigerantcomposition under pressure, in a cylinder can fitted with an outletcompatible with a chlorodifluoromethane recharging manifold of theapparatus.
 33. (canceled)
 34. A refrigerant composition comprising acombination of refrigerant gases, the refrigerant gases consisting of ablend of tetrafluoroethane and pentafluoroethane, wherein in therefrigerant composition said pentafluoroethane is present in an amountof 59% to 57% by weight and said tetrafluoroethane is present in anamount of 41% to 43% by weight of the combined weight of thepentafluoroethane and tetrafluoroethane on the basis of the combinedweights of said pentafluoroethane, and said tetrafluoroethane totaling100% and wherein the tetrafluoroethane is 1,1,1,2-tetrafluoroethane.35.-36. (canceled)
 37. In the apparatus of claim 30, wherein theapparatus is selected from the group consisting of refrigerationequipment, air-conditioning equipment, and HVAC equipment.
 38. In theapparatus of claim 30, wherein the refrigerant composition includes anadditive selected from the group consisting of an acrylic polymer, acorrosion inhibitor, a surfactant, a foaming agent, and mixturesthereof.
 39. The method according to claim 32, wherein the apparatus isselected from the group consisting of refrigeration equipment,air-conditioning equipment, and HVAC equipment.
 40. The method accordingto claim 32, wherein the substitute refrigerant composition includes anadditive selected from the group consisting of an acrylic polymer, acorrosion inhibit, a surfactant, a foaming agent, and mixtures thereof.41.-46. (canceled)